Methods of making self-steaming compositions and articles comprising such compositions

ABSTRACT

A method of making a self-steaming composition is provided, said method comprising mixing a fuel component, a water manager component, and water, wherein the fuel component comprises carbon and wherein the method comprises prewetting the carbon prior to mixing the carbon with the water manager component.

This application is a divisional application of U.S. patent applicationSer. No. 11/070,764, filed on Mar. 2, 2005, which claims the benefit ofU.S. Provisional Application No. 60/574,809, filed on May 27, 2004, thecontents of both of which are hereby incorporated by reference as if setforth fully herein.

FIELD OF THE INVENTION

The present invention is directed to methods for the preparation ofcompositions which are self-steaming, including those which utilizesteam generation for treating fabrics, providing health benefits,aesthetic benefits, or the like.

BACKGROUND OF THE INVENTION

Disposable thermal devices based on, for example, iron oxidation areknown. However, many such devices are limited in their utility, such asfor use merely to heat desired components including mammalian jointconstituents, such as in the knee, elbow, and the like. While suchdevices deliver desired and controlled heat, it would be advantageous toexpand the utility of such devices, such to capitalize upon the uniquecapability of heat generation without need for an external energysource.

The present invention advances the utility of exothermic compositions byproviding means for self-steaming which is in addition to the exothermiccharacter of such composition. However, as could be imagined, it isdifficult to practically deliver such compositions, given the inherentneed for retaining water in or around the exothermic composition withoutproblematic flooding. The invention herein overcomes such obstacle byproviding portable and/or disposable compositions and articles which areused as a source of steam and heat, through use of a water managercomponent, which advantageously holds moisture within the presentcompositions and articles, allowing for later release as steam when thecomposition or article is ready for use. Particular embodiments of theinvention are herein directed as various solutions to the foregoingproblems.

The invention may be utilized in a wide variety of applications. Forexample, it is highly advantageous to provide means for cleaning orrefreshing fabrics without the need for labor-intensive pressing, or thelike. In addition, the present articles may be directed to varioushealth care applications. To illustrate, the article may be a vaporizer,such as a self-steaming vaporizer or vapor therapy humidifier. Notlimited to this application, the article may serve to moisturize dry orirritated respiratory passages or relieve cough or other symptomsassociated with cold. These and other benefits of the present inventionare further described herein.

SUMMARY OF THE INVENTION

The present invention is directed to compositions which are exothermicupon contact with oxygen and are self-steaming.

The various embodiments of the invention include compositionscomprising:

-   -   (a) a fuel component;    -   (b) a water manager component; and    -   (c) water.

In one embodiment, the water manager component, has a mean particle sizedistribution of greater than about 250 microns.

Alternatively or additionally, the ratio of the water manager componentto the water is from about 0.001:1 to about 0.2:1, by weight.

Alternatively or additionally, the fuel component comprises sponge iron.

Alternatively or additionally, the composition comprises a volatilecomponent.

In yet another embodiment, articles comprising the compositions aredescribed. Further, methods of making the compositions are described.

DETAILED DESCRIPTION OF THE INVENTION

Various documents including, for example, publications and patents, arerecited throughout this disclosure. All such documents are herebyincorporated by reference.

All percentages and ratios are calculated by weight unless otherwiseindicated. All percentages and ratios are calculated based on the totalcomposition unless otherwise indicated.

Referenced herein are trade names for components including variousingredients utilized in the present invention. The inventors herein donot intend to be limited by materials under a certain trade name.Equivalent materials (e.g., those obtained from a different source undera different name or reference number) to those referenced by trade namemay be substituted and utilized in the descriptions herein.

In the description of the invention, various embodiments and/orindividual features are disclosed. As will be apparent to the ordinarilyskilled practitioner, all combinations of such embodiments and featuresare possible and can result in preferred executions of the presentinvention.

The compositions herein may comprise, consist essentially of, or consistof any of the elements as described herein.

While various embodiments and individual features of the presentinvention have been illustrated and described, various other changes andmodifications can be made without departing from the spirit and scope ofthe invention. As will be also be apparent, all combinations of theembodiments and features taught in the foregoing disclosure are possibleand can result in preferred executions of the invention.

As used herein, the term “self-steaming” means possessing the ability togenerate and release steam or vapor from water present in the referencedcomposition upon contact with gas comprising oxygen, such as air. Inaccordance with the present invention, the self-steaming compositions donot rely on the input of energy from sources separate from theself-steaming composition.

As used herein, the term “steam” means vaporized water as an invisiblegas and/or the visible mist that condenses therefrom.

Compositions of the Present Invention

The present invention is directed to compositions which are exothermicupon contact with oxygen and are self-steaming. The various embodimentsof the invention include compositions comprising:

-   -   (a) a fuel component;    -   (b) a water manager component; and    -   (c) water.

In one embodiment, the water manager component has a mean particle sizedistribution of greater than about 250 microns.

Alternatively or additionally, the ratio of the water manager componentto the water is from about 0.001:1 to about 0.2:1, by weight.

Alternatively or additionally, the fuel component comprises sponge iron.

Alternatively or additionally, the composition further comprises avolatile component.

The various components of various embodiments of the compositions aredescribed as follows:

The Fuel Component

The present compositions comprise a fuel component. As used herein, thefuel component comprises one or more materials which are self-steamingin conjunction with the remaining components of the composition(including the water manager component and water). In particular, thefuel component is the reactant for the self-steaming process uponcontact with oxygen.

A variety of materials will be understood by those of ordinary skill inthe art as being useful as the fuel component. See e.g., U.S. Pat. Nos.5,918,590 and 5,984,995.

In one embodiment herein, the fuel component may comprise a materialselected from the group consisting of metals, metal salts, carbon, andmixtures thereof. For example, in one embodiment, the fuel component maycomprise iron, a metal salt, and activated carbon.

Metals

Metals which may be used herein will be well-known to those of ordinaryskill in the art. For example, iron, aluminum, zinc, copper, lead, andthe like may be utilized.

In one embodiment, the metal is iron. Iron is the anode for theelectrochemical reaction involved in the exothermic oxidation of iron.Suitable sources for iron include cast iron powder, reduced iron powder,electrolytic iron powder, scrap iron powder, sponge iron, pig iron,wrought iron, steel, iron alloy, and the like, all of which shallinclude treated varieties of these irons. There is no particularlimitation to their purity, kind, and the like, so long as it can beused to generate steam or vapor as part of the self-steamingcomposition.

Sponge iron is one example of the iron, which may be particularlyadvantageous due to the high internal surface area of this iron source.As the internal surface area is orders of magnitude greater than theexternal surface area, reactivity may not be controlled by particlesize. Non-limiting examples of sponge iron include M-100 and F-417,commercially available from Hoeganaes Corp., N.J.

Sponge iron is a material utilized in the steel making industry as abasic source for the production of steel. Without intending to belimited by any method of production, sponge iron may be produced byexposing hematite (Fe₂O₃) iron ore in comminuted form to a reducing gasenvironment at temperatures somewhat below blast furnace temperatures.The production of sponge iron is the subject of a large number ofpatents, including: U.S. Pat. Nos. 2,243,110; 2,793,946; 2,807,535;2,900,247; 2,915,379; 3,128,174; 3,136,623; 3,136,624; 3,136,625;3,375,098; 3,423,201; 3,684,486; 3,765,872; 3,770,421; 3,779,741;3,816,102; 3,827,879; 3,890,142; and 3,904,397.

The ordinarily skilled artisan will be able to manipulate the amount ofmetal present within the composition in accordance with the level ofheat and/or steam desired. As an example, the compositions may comprisefrom about 30% to about 95%, alternatively from about 40% to about 85%,alternatively from about 50% to about 70% of the metal, by weight of thecomposition.

Metal Salts

Any of various metal salts may be utilized in the present compositions.The metal salt serves as a reaction promoter for activating the surfaceof the metal to ease the oxidation reaction with air and provideselectrical conduction to the exothermic composition to sustain thecorrosive reaction.

The metal salts useful in the present compositions include sulfates suchas ferric sulfate, potassium sulfate, sodium sulfate, manganese sulfate,magnesium sulfate; and chlorides such as cupric chloride, potassiumchloride, sodium chloride, calcium chloride, manganese chloride,magnesium chloride and cuprous chloride. Also, carbonate salts, acetatesalts, nitrates, nitrites and other salts can be used. In general,several suitable alkali, alkaline earth, and transition metal saltsexist which can also be used, alone or in combination, to sustain thecorrosive reaction of the metal. Exemplary metal salts include sodiumchloride, cupric chloride, and mixtures thereof.

The ordinarily skilled artisan will be able to manipulate the amount ofmetal salts present within the composition in accordance with the levelof heat and/or steam desired. Typically, the exothermic compositioncomprises from about 0.5% to about 10%, alternatively from about 1% toabout 5% metal salts, all by weight of the composition.

Carbon

Carbon (including carbonaceous material) selected from the groupconsisting of activated carbon, non-activated carbon, and mixturesthereof may be used in the compositions herein. Activated carbon may beused as a catalyst for the reactions generated herein. Specifically,activated carbon, when wet, has the ability to adsorb oxygen. Activatedcarbon may also serve as the cathode for the electrochemical reactioninvolved in the exothermic oxidation of metal. Furthermore, activatedcarbon serves as a water-releasing agent as it helps facilitate therelease of water due to its extremely porous inner structure, thusallowing it to temporarily retain water until the steam generationprocess begins. Activated carbon may also adsorb odors such as thosethat may be caused by the oxidation of metal.

Activated carbon prepared from coconut shell, wood, charcoal, coal, bonecoal, and the like are useful, but those prepared from other rawmaterials such as animal products, natural gas, fats, oils and resinsare also useful in the particulate exothermic composition optionallyused herein. There are no limitations to the kinds of activated carbonused; for example, the preferred activated carbon has superior waterholding capabilities and the different carbons may be blended to reducecost. Therefore, mixtures of the above carbons are useful in the presentinvention as well.

The ordinarily skilled artisan will be able to manipulate the amount ofcarbon present within the composition in accordance with the level ofheat and/or steam desired. For example, the composition may comprisefrom about 0.5% to about 25%, alternatively 1% to about 20%,alternatively from about 2% to about 15%, all by weight of thecomposition.

The Water Manager Component

The present compositions comprise a water manager component. As usedherein, the water manager component comprises one or more materialswhich enable the retention of water physically or chemically within thecomposition, such that the composition will release the water as steam.In particular, the water manager component is the component whichenables the retention of sufficient water within the composition, suchthat the water may later be released upon self-steaming. While notintending to be bound by theory, it is believed that the water managercomponent can facilitate the generation of an increased volume of steamby releasing water at a controlled rate. Furthermore, the water managercomponent can prevent or inhibit water from entering, or beingmaintained in, the interstitial voids of the various particles of thecomposition, thereby helping to prevent or inhibit flooding.

A variety of materials will be understood by those of ordinary skill inthe art as being useful as the water manager component. See e.g., U.S.Pat. Nos. 5,918,590 and 5,984,995. For example, those having capillaryfunction and/or hydrophilic property may be utilized. To illustrate, thecomposition may comprise a material selected from the group consistingof vermiculite, porous silicates, wood powder, wood flour, cotton,paper, vegetable matter, absorbent gelling material,carboxymethylcellulose salts, inorganic salts, and mixtures thereof.

As an example, an absorbent gelling material may be used. As iswell-known, absorbent gelling materials are materials havingfluid-absorbing properties. Such materials form hydrogels on contactwith water. One type of hydrogel-forming, absorbent gelling material isbased on a polyacid, for example polyacrylic acid. Hydrogel-formingpolymeric materials of this type are those which, upon contact withliquids such as water, imbibe such fluids and thereby form the hydrogel.These preferred absorbent gelling materials will generally comprisesubstantially water-insoluble, slightly cross-linked partiallyneutralized, hydrogel-forming polymer materials prepared frompolymerizable, unsaturated, acid-containing monomers. In such materials,the polymeric component formed from unsaturated, acid-containingmonomers may comprise the entire gelling agent or may be grafted ontoother types of polymer moieties such as starch or cellulose. Acrylicacid grafted starch materials are of this latter type. Thus, certainabsorbent gelling materials include hydrolyzed acrylonitrile graftedstarch, acrylic acid grafted starch, polyacrylate, maleicanhydride-based copolymer, and combinations thereof. Absorbent gellingmaterials may include the polyacrylates and acrylic acid grafted starch.

The ordinarily skilled artisan will be able to manipulate the amount ofwater manager component present within the composition in accordancewith the level of steam desired. For example, the composition-maycomprise from about 0.1% to about 30%, alternatively from about 0.5% toabout 20%, alternatively from about 1% to about 10% water managercomponent, all by weight of the composition.

Water

The water used herein may be from any appropriate source. For example,tap water, distilled water, or deionized water, or any mixture thereof,may be used.

The water may be incorporated directly in the form of liquid water, orwater that is physically or chemically held to the separate watermanager component, or any combination thereof.

The ordinarily skilled artisan will be able to manipulate the amount ofwater present within the composition in accordance with the level ofheat and/or steam desired. When water is consumed in a reaction whereheat and steam are released, an excess of water beyond thestoichiometric amount need for the reaction is necessarily added toprovide a source of water used for producing steam. For example, thecomposition may comprise from about 1% to about 60%, alternatively fromabout 10% to about 30% water, all by weight of the composition.

Particle Size

In one embodiment herein, the present compositions advantageouslycomprise the fuel component and the water manager component, wherein thefuel component may have a first mean particle size distribution and thewater manager component may have a second mean particle sizedistribution.

For example, it is found herein that distinct advantages relative to theart are provided wherein the water manager component has a relativelyhigh mean particle size distribution. For example, increasing the meanparticle size distribution may have advantages in terms of enhancingsafety upon preparing the present compositions, as larger particle sizedistribution may decrease risks associated with particle inhalation andother respiratory effects.

To illustrate, in one embodiment of the invention, the water managercomponent (or, alternatively or additionally where explicitly specified,any individual material thereof) has a mean particle size distributiongreater than about 250 microns, or at least about 400 microns, or fromabout 400 microns to about 800 microns. In an additional or alternativeembodiment herein, the fuel component (or, alternatively or additionallywhere explicitly specified, any individual material thereof (e.g., iron)has a mean particle size distribution of at least about 100 microns, orfrom about 100 microns to about 300 microns.

As used herein, and as will be commonly understood in the art, the term“mean particle size distribution,” with reference to a given component,is the mean value of the particles present in the component based on thesizes of the individual particles in the component. The mean particlesize distribution of the given component may be measured using a HORIBALA-910 laser scattering particle size distribution analyzer (Horiba,Calif.), or other instrument providing substantially similar results.

In this embodiment, the relative increase of these particle sizedistributions is preferred in order to minimize segregation effects.Reducing segregation effects among components allows desired thermaland/or steaming effects. In particular, minimizing segregation effectsis desirable when the composition is used to make multi-cell heat packswhere the cell weight is in order of 5 grams or less. Fillingmulti-cells with the right amount of chemistry requires a highlyflow-able chemistry pre-mix composition, such as the pre-mix compositiondefined herein. A pre-mix composition having high flow ability wouldalso be prone to segregation, especially if the particles differconsiderably in particle size. It is known that the size differencebetween the water manager and fuel component can vary. The sizedifference can be contributed to the belief that fines (such as, forexample, fine iron powder) is necessary for rapidity of reaction rate.On the other hand, the particle size of the water manager needs to belarge in order to maximize water holding capacity in its inner structure(i.e. vermiculite) or to minimize respiratory dusting issues (i.e. AGM).Indeed, it is found herein that the aforementioned relatively increasedmean particle size distributions reduce segregation effects amongcomponents within the composition. This allows for the high speedproduction of multi-cell heat packs that provide more than 8 hours oftherapeutic heat and fast self steaming multi-cell heat packs. Withoutintending to be limited by theory, this is based on a finding that theporosity of the mixture of particles utilized may govern reaction rate,rather than (or in addition to) surface area of the metal. Thus, themulti-cell heat packs used for therapeutic heating has a high reactionefficiency (e.g., less metal or other material may be necessary) sincethe composition has a high level of moisture needed for the reaction,yet the high level of water added does not “flood the reaction”(Reaction fails to heat up due to the inability of oxygen to diffusethrough the excess water that fills the interstitial particle voids.).Similarly, the high porosity of the chemistry composition enables selfsteaming multi cell heat packs to quickly heat up to steamingconditions.

Ratio of Water Manager Component to Water

In an additional or alternative embodiment herein, the ratio of watermanager component to water is manipulated. Indeed, it is found hereinthat use of the highly efficient water manager components herein enablesa decreased level of water manager component relative to the water,which is desirable for a variety of reasons, includingcost-effectiveness of the composition (and therefore availability of thecomposition to the user). For example, in one embodiment herein, theratio of the water manager component to the water is from about 0.001:1to about 0.2:1, or from about 0.01:1 to about 0.17:1, or from about0.05:1 to about 0.12:1, all by weight.

Articles of the Present Invention

The present invention is further directed to articles comprising any ofthe various compositions as described herein.

Any of the various compositions described herein may be associated witha substrate or other material which enables convenient use for any of avariety of applications.

For example, the present articles may be directed to various health careapplications. To illustrate, the article may be a vaporizer, such as aself-steaming vaporizer or vapor therapy humidifier. Not limited to thisapplication, the article may serve to moisturize dry or irritatedrespiratory passages or relieve cough or other symptoms associated withcold. As a non-limiting example, the article of the present inventionmay be a commercial vaporizer, such as a VICKS® Vaporizer as marketed byKaz Corporation, New York, N.Y., except that it is adapted to contain aself-steaming (including, vaporizing) composition as described hereinsuch that the vaporizer is portable and not dependent upon an externalsource of energy for operation. In this embodiment, a sub-articlecomprising the composition of the present invention is contained withinthe vaporizer article, such that upon activation the composition isself-steaming (including, self-vaporizing) for the benefit of the user.

As another example, the compositions or articles herein may be used invarious fabric care applications, for example, to impart fragrance tofabrics (such as, for example, clothing, linen, draperies, clothingaccessories, leather, floor coverings, tote bags, furniture covers,tarpaulins, shoes, and the like. Articles in accordance with thisembodiment are described in co-pending patent application to Roselle etal., assigned to The Procter & Gamble Co., and filed on May 26, 2004.

In order to enable the various embodiments of the present articles, thearticles may comprise a thermal pack. In one particular embodimentherein, the thermal packs may have at least one continuous layer of amaterial which preferably exhibits specific thermophysical properties,and optionally one or more (including two or more) individual heat cellswhich preferably comprise a composition as described herein, spacedapart and fixed within or to the structure of the thermal pack. Thecells may be of a unified structure, comprising the exothermic andself-steaming composition, enclosed within two layers, wherein at leastone layer may be permeable to air, capable of providing long lastingheating, and having specific physical dimensions and fillcharacteristics. These cells can be used as individual temperaturecontrol units, or in a thermal pack comprising a plurality of individualcells. Thermal packs have been widely disclosed in the art, such as atU.S. Pat. No. 6,020,040. Alternatively, the thermal pack is such that iscontains a composition as described herein in a loose configuration,wherein the various particles of the composition may be free-flowingwithin the thermal pack. The thermal pack, regardless of configuration,typically comprises a material which is permeable to air, such that thecomposition may initiate the self-steaming process when ready for use.

By way of example, the thermal pack may be constructed as a bag or otherenclosure which surrounds the composition as described herein, whereinthe composition may be free-flowing within the enclosure. The thermalpack is permeable to air. The thermal pack may then be further enclosedin a device which is impermeable to air, in order to avoid exposure ofthe compositions to air or other source of oxygen until the article orcomposition is intended for use. By way of further example, anotherthermal pack may be constructed by forming a pocket in a base material.The pocket is filled with a composition as described herein. Afterfilling the pocket, a cover material is placed over the pocket and heatsealed to the base material around the periphery of the pocket,encapsulating the exothermic and self-steaming composition in the heatcell.

The heat cells can have any geometric shape, e.g., disk, triangle,square, cube, rectangle, cylinder, ellipsoid and the like, all, some, ornone of which may contain a hole through the middle or other reservoir.For example, the shape may be an ellipsoid geometry. Alternatively,cells having geometric shapes other than an ellipsoid shape, such as adisk shape may be used.

The ordinarily skilled artisan will understand that, wherein a giventhermal pack comprises a plurality of heat cells, the heat cells may beof various shapes or sizes and therefore need not (but may be) uniform.

Oxygen permeability, allowing enhancement of the exothermic andself-steaming reaction, may optionally be provided by selectingmaterials for the article that have the specifically desiredpermeability properties. It is particularly useful to utilize materialsas part of the article which enable relatively high oxygen permeabilityfor use with the self-steaming materials herein. The desiredpermeability properties may be provided by inherently porous films or byfilms which have pores or holes formed therein. The formation of theseholes/pores may be via extrusion cast/vacuum formation or by hot needleaperturing.

For example, oxygen permeability of at least about 10 ft³/min,alternatively at least about 20 ft³/min, alternatively at least about 70ft³/min, all measured in accordance with the following method, whereinmaximum oxygen permeability is only optionally limited by ability of thereferenced material to inhibit the self-steaming composition fromflowing through the aperture. As a further example, the oxygenpermeability may be from about 10 ft³/min to about 400 ft³/min,alternatively from about 20 ft³/min to about 150 ft³/min, alternativelyfrom about 70 ft³/min to about 130 ft³/min, all measured in accordancewith the following method. Oxygen permeability is measured utilizing aTexTest FX3300 instrument, commercially available from TexTest AG,Switzerland. The instrument is fitted with a 38 cm² test head. Thepermeability of a given material is measured, with a test pressure setat 125 Pa, in accordance with the manufacturer specifications, generallyas follows: the material for measurement is placed over the vacuum portand under the test head of the instrument, minimizing any wrinkles inthe material to the extent feasible. The test is commenced by pressingon the test head claming lever, engaging the vacuum. The instrumentreaches equilibrium, and then the displayed value is recorded.

The velocity, duration, and temperature of the thermogenic oxidationreaction of the exothermic, self-steaming composition can be, in part,controlled as desired by changing the area of contact with air, morespecifically, by changing the oxygen diffusion/permeability. Othermethods of modifying reaction include choice of component within thecomposition, for example, by choosing sponge iron, modifying particulatesize, or the like as described herein above.

Oxygen permeable materials may be made from any number of differentmaterials. For example, such materials may include, but are not limitedto, woven and knit fabrics, nonwovens (e.g., spunbound nonwoven orcarded nonwovens), and the like. For example, a suitable nonwoven isavailable from PGI (Polymer Group International) of Waynesboro, Va., asmaterial number W502FWH.

One or more oxygen impermeable materials may also be utilized toconstruct the thermal pack. Such materials may include, but are notlimited to, polyethylene, polypropylene, nylon, polyester, polyvinylchloride, polyvinylidene chloride, polyurethane, polystyrene, saponifiedethylene-vinyl acetate copolymer, ethylene-vinyl acetate copolymer,natural rubber, reclaimed rubber, synthetic rubber, and mixturesthereof. These materials may be used alone, preferably extruded, morepreferably coextruded, most preferably coextruded with a low melttemperature polymer including, but not limited to, ethylene vinylacetate copolymer, low density polyethylene, and mixtures thereof.

For example, the material may comprise polypropylene, such as acoextruded material comprising polypropylene. For example, a suitableheat-sealable film is a polypropylene/ethylene vinyl acetate (PP/EVA)film available from Clopay Plastics of Cincinnati, Ohio, as materialnumber DH245.

Attachment of the various materials of the articles described herein maybe achieved by any number of attachment means known in the art. Theseinclude, but are not limited to, hot melt adhesive including spiralsprays, meltblown, control coat, and the like, latex adhesives appliedvia spray, printing, gravure, and the like, thermal bonding, ultrasonic,pressure bonding, and the like. For example, an adhesive layer may beused. One particular method includes a hot melt adhesive available as70-4589 from National Starch and Chemical Co., Bridgewater, N.J.,applied via a hot melt system.

The present compositions are exothermic upon contact with oxygen and areself-steaming. As such, it may be important to avoid exposure of thecompositions to air or other source of oxygen until the composition isintended for use. In one embodiment of the present invention, articlescomprising any of the various compositions described herein and asecondary enclosure which contains the composition, wherein theenclosure is impermeable to air, are further provided. See e.g., U.S.Pat. No. 4,649,895. Alternatively or additionally, other means may alsobe used to prevent an oxidation reaction from occurring before desired,such as oxygen-impermeable removable adhesive strips placed over theaeration holes such that, when the strips are removed, oxygen is allowedto enter the cells, thus activating the oxidation reaction.

For example, in one non-limiting embodiment, the self-steamingcomposition may be activated as follows: The article comprising thecomposition may include an oxygen impermeable plastic overwrap. Atear-tab or notch may be included on the overwrap for easy access by auser. Instructions may be included with the enclosure instructing a userto tear open the overwrap to remove the article comprising theself-steaming composition. This opening action immediately mixesproximal oxygen contained in the ambient air with the composition toinitiate the self-steaming process.

For practicality, the self-steaming process is typically designed insuch a way that the steaming occurs at the desired time. As such, thecomposition is generally contained or presented in a manner such thatthe steaming can be started or activated as needed. For example, thepresent self-steaming compositions may be contained within an enclosurewhich is impermeable to air, wherein steaming may be started oractivated through disruption of the enclosure.

As an additional or alternate example, for compositions that react toform steam, there may be a barrier between reactive components toprevent the reaction from occurring until desired. In this optionalembodiment, the activation of the composition may be achieved by aremoval or disruption of a barrier which allows the composition tointeract in a manner that will create the desired self-steaming effect.

Upon activation, the self-steaming composition may generate at leastabout 2×10⁻⁵, or at least about 5×10⁻⁵ grams/minute of steam.

The Volatile Component

In one embodiment herein, the compositions or articles may comprise avolatile component. The volatile component comprises one or more of anymaterials which are volatile, at ambient pressure, at temperaturesgreater than about 25° C., or greater than about 30° C., or greater thanabout 34° C., or greater than about 39° C., or greater than about 42° C.The volatile component may include perfumes, silicones, essential oilsand aromatic oils; these are of course well-known in the art.

For example, the present compositions or articles herein may be used invarious health care applications. To illustrate, the article may be aself-steaming vaporizer. Not limited to these applications, the volatilecomponent of the composition used in such article may comprise, forexample, one or more materials which serve to moisturize dry orirritated respiratory passages or relieve cough or other symptomsassociated with cough and cold. Non-limiting examples of such materialsinclude essential oils and other materials, including camphor, menthol,eucalyptus, peppermint, spearmint, methyl salicylate, bornyl acetate,lavender, ephedrine, angelica root, aniseed, basil, bay, bergamot,cajeput, cardamom, cassia, cedarwood, chamomile, sage, clove, cinnamon,coriander, cumin, fennel, frankincense, geranium, ho-wood, lemongrass,lemon, litsea, majoram, melissa, myrrh, myrtle, niaouli, neroli, nutmeg,orange, palmarosa, patchouli, pimento berry, pine needle, ravensaraaromatica, rosewood, rosemary, tea tree, thyme, verbena, mixturesthereof, and the like. The preferred volatile components for use in thepresent invention include eucalyptus, camphor, menthol, and mixturesthereof.

As another example, the compositions or articles herein may be used invarious fabric care applications, for example, to impart fragrance tofabrics (such as, for example, clothing, linen, draperies, clothingaccessories, leather, floor coverings, tote bags, furniture covers,tarpaulins, shoes, and the like. Not limited to these applications, thevolatile component may comprise, for example, one or more perfumes.

Perfumes are widely known in the art and, of course, conventionalperfumes may be utilized. Selection of the perfume used herein may bebased upon the desired fragrance characteristics imparted by thecomposition or article upon self-steaming.

Non-limiting perfumes include those described in U.S. Pat. Nos.4,145,184; 4,209,417; 4,515,705; and 4,152,272. Additionally, manyperfumes, along with their odor and/or flavor characters, and theirphysical and chemical properties, such as boiling point and molecularweight, are disclosed in “Perfume and Flavor Chemicals (AromaChemicals),” Steffen Arctander (1969).

Moreover, further non-limiting examples of perfumes include: anethole,benzaldehyde, benzyl acetate, benzyl alcohol, benzyl formate, iso-bornylacetate, camphene, cis-citral (neral), citronellal, citronellol,citronellyl acetate, para-cymene, decanal, dihydrolinalool,dihydromyrcenol, dimethyl phenyl carbinol, eucalyptol, geranial,geraniol, geranyl acetate, geranyl nitrile, cis-3-hexenyl acetate,hydroxycitronellal, d-limonene, linalool, linalool oxide, linalylacetate, linalyl propionate, methyl anthranilate, alpha-methyl ionone,methyl nonyl acetaldehyde, methyl phenyl carbinyl acetate, laevo-menthylacetate, menthone, iso-menthone, myrcene, myrcenyl acetate, myrcenol,nerol, neryl acetate, nonyl acetate, phenyl ethyl alcohol, alpha-pinene,beta-pinene, gamma-terpinene, alpha-terpineol, beta-terpineol, terpinylacetate, and vertenex (para-tertiary-butyl cyclohexyl acetate). Somenatural oils also contain large percentages of highly volatile perfumeingredients. For example, lavandin contains as major components:linalool; linalyl acetate; geraniol; and citronellol. Lemon oil andorange terpenes both contain about 95% of d-limonene.

Other non-limiting examples include amyl cinnamic aldehyde, iso-amylsalicylate, beta-caryophyllene, cedrene, cinnamic alcohol, coumarin,dimethyl benzyl carbinyl acetate, ethyl vanillin, eugenol, iso-eugenol,flor acetate, heliotropine, 3-cis-hexenyl salicylate, hexyl salicylate,lilial (para-tertiarybutyl-alpha-methyl hydrocinnamic aldehyde),gamma-methyl ionone, nerolidol, patchouli alcohol, phenyl hexanol,beta-selicarb, trichloromethyl phenyl carbinyl acetate, triethylcitrate, vanillin, and veratraldehyde. Cedarwood terpenes are composedmainly of alpha-cedrene, beta-cedrene, and other sesquiterpenes.

Other non-limiting examples include benzophenone, benzyl salicylate,ethylene brassylate, galaxolide(1,3,4,6,7,8-hexahydro-4,6,6,7,8,8-hexamethyl-cyclopenta-gama-2-benzopyran)hexylcinnamic aldehyde, lyral (4-(4-hydroxy-4-methylpentyl)-3-cyclohexene-10-carboxaldehyde), methyl cedrylone, methyldihydro jasmonate, methyl-beta-naphthyl ketone, musk indanone, muskketone, musk tibetene, and phenylethyl phenyl acetate.

The volatile component can be delivered by direct volatilization of thecomponent by the steam generated. In this case, the volatile componentis incorporated directly within the self-steaming composition oralternatively in or on a substrate or other material of the article,wherein the steam is in thermal communication with the material so as torelease the volatile component from the material. Non-limiting examplesinclude wherein a perfume is incorporated directly in the self-steamingcomposition or alternately wherein a perfume is impregnated onto amaterial (for example, a non-woven substrate or a fabric softening sheet(such as BOUNCE, commercially available from The Procter & Gamble Co.,Cincinnati, Ohio) that is in thermal communication with theself-steaming composition. The steam volatilizes the perfume such thatthe perfume is carried away along with the steam.

The volatile component may also be delivered in the form of anazeotrope. As the steam is formed from water, a consistent mix of waterand volatile component can be volatilized off in the form of anazeotrope.

Other Optional Components

Other optional components of the present compositions or articles hereinmay include agglomeration aids such as gelatin, natural gums, cellulosederivatives, cellulose ethers and their derivatives, starch, modifiedstarches, polyvinyl alcohols, polyvinylpyrrolidone, sodium alginates,polyols, glycols, corn syrup, sucrose syrup, sorbitol syrup and otherpolysaccharides and their derivatives, polyacrylamides,polyvinyloxoazolidone, and maltitol syrup; dry binders such asmaltodextrin, sprayed lactose, co-crystallized sucrose and dextrin,modified dextrose, sorbitol, mannitol, microcrystalline cellulose,microfine cellulose, pre-gelatinized starch, dicalcium phosphate, andcalcium carbonate; oxidation reaction enhancers such as elementalchromium, manganese, or copper, compounds comprising said elements, ormixtures thereof; hydrogen gas inhibitors such as inorganic or organicalkali compounds or alkali weak acid salts including sodium thiosulfate,sodium sulfite, sodium hydroxide, potassium hydroxide, sodium hydrogencarbonate, sodium carbonate, calcium hydroxide, calcium carbonate, andsodium propionate; fillers such as natural cellulosic fragmentsincluding wood dust, cotton linter, and cellulose, synthetic fibers infragmentary form including polyester fibers, foamed synthetic resinssuch as foamed polystyrene and polyurethane, and inorganic compoundsincluding silica powder, porous silica gel, sodium sulfate, bariumsulfate, iron oxides, and alumina; and anti-caking agents such astricalcium phosphate and sodium silicoaluminate. Such components alsoinclude thickeners such as cornstarch, potato starch,carboxymethylcellulose, and alpha-starch, and surfactants such as thoseincluded within the anionic, cationic, nonionic, zwitterionic, andamphoteric types. Still other optional components may be included withinthe compositions or articles herein, as appropriate, including extendingagents such as metasilicates, zirconium, and ceramics. Other optionalcomponents herein include one or more benefit agents. Where present, thebenefit agent selected will be dependent upon the intended use of thecomposition or article of the present invention.

For example, the compositions or articles herein may be used toself-steam fabrics (such as, for example, clothing, linen, draperies,clothing accessories, leather, floor coverings, tote bags, furniturecovers, tarpaulins, shoes, and the like. In such an instance, thebenefit agent may include, for example, one or more softening agents,crispening agents, water and/or stain repellents, refreshing agents,antistatic agents, antimicrobial agents, durable press agents, wrinkleresistant agents, wrinkle release agents, odor resistance agents,abrasion resistance agents, solvents, and mixtures thereof. Non-limitingexamples of benefit agents include silicone, starch, wrinkle-releasingagent, perfume, surfactants, preservatives, bleaches, auxiliary cleaningagents, fabric shrinkage reducing compositions, organic solvents andmixtures thereof. Non-limiting examples of organic solvents includeglycol ethers, specifically, methoxy propoxy propanol, ethoxy propoxypropanol, propoxy propoxy propanol, butoxy propoxy propanol, butoxypropanol, ethanol, isopropanol and mixtures thereof.

The compositions or articles of the present invention may also includeone or more other optional signal components, a non-limiting example ofwhich is a component that enables communication of the status of theself-steaming process or condition of the composition or article to auser. For example, the compositions or articles may enable a signalwhich indicates when steaming has commenced and/or concluded.Non-limiting examples of signals which may be enabled include color,sound, and/or olfactory signals.

One non-limiting example of such a signal component includes acolor-changing dye or paint that is sensitive to changes in temperatureor humidity. An example of a suitable color changing paint is KROMAGEN75 manufactured by TMC U.S.A. of Glenview, Ill. As an example, whereinthe signal component is included, the may comprise from about 0% toabout 20% of the signal component, by weight of the composition orarticle.

Methods of Production

The various components of the self-steaming compositions and articlesherein may be blended together in accordance with any number of variousprocesses. For example, when utilizing a self-steaming benefitcomposition derived from iron oxidation as described above, thefollowing non-limiting method may be used for blending the materials.

While the compositions are articles described herein are not limited byany particular method of production, the compositions may optionally beprepared through a method which includes prewetting any carbon presentin the composition prior to adding to other materials or components.Indeed, it is found herein that this may be particularly important inorder that the exothermic and self-steaming processes occur over arelatively long duration of time. For example, without intending to belimited by theory, it is found that, due to the water managercomponent's higher affinity to water, sufficient hydration of the carbonneeded for increasing its catalytic activity may not be achieved. Byprewetting the carbon, at least a portion of the water is reserved forincreasing the catalytic activity of the carbon. The water is tightlybound by the carbon and made relatively inaccessible to the watermanager component.

In accordance with this, a pre-mix may be formed by prewetting activatedcarbon with the water and adding in the iron, the water managercomponent, salt and sodium thiosulfate and any other additionalcomponents which may be used. For example, if a volatile component wereto be added in it could be added to the activated carbon, added to thepre-mix formed, added to a substrate (for example, a non-woven, oxygenpermeable substrate) that contains the mixture, or any combinationthereof.

EXAMPLES

The following are examples of the present components, compositions, andarticles. The compositions are prepared utilizing conventional processesor, preferably, the methods of production described herein. The examplesare provided to illustrate the invention and are not intended to limitthe scope thereof in any manner.

Example 1

A self-steaming composition for use in accordance with the presentinvention may be prepared as follows:

A pre-mix containing a fuel component, a water manager component, andwater is prepared as follows: Activated carbon (5.58 kg) is added to amixer, such as a Littleford Day Mixer. Water (4.28 kg) is added to themixer, and the mixture mixes for about 10 minutes. Sponge iron (83.14kg) is added to the mixer, and the mixture mixes for about 3 minutes.Absorbent gelling material (a polyacrylate, 7 kg) is added to the mixer,and the mixture mixes for about 12 minutes. This pre-mix is then addedto a container.

Brine is prepared as follows: Water (88.3 kg) is added to a mixer.Sodium chloride (10.4 kg) and sodium thiosulfate (1.3 kg) is added tothe mixer, and the mixture mixes for about 15 minutes. The resultingbrine is then added to a separate container. The ratio of premix tobrine can be varied to modify the amount of steam generation desired.For example, a ratio of 2:1 premix:brine, by weight, may be used.

The pre-mix and the brine solution are combined prior to packing in afinal overwrap container or, alternatively, added to a substrate of anarticle in accordance with the present invention to form a thermal pack.If desired, one or more volatile components may be added to thecomposition contained within the final overwrap container, or, whereapplicable, the composition added to the substrate or directly to thesubstrate of the article. A non-limiting example includes adding thevolatile component to the activated carbon, adding to the pre-mixformed, adding to a non-woven substrate that contains the composition,or combinations thereof.

Example 2

A disposable, self-steaming composition in accordance with the presentinvention is used to prepare an article suitable for a variety ofapplications, including steaming fabric or utilizing within a vaporizerfor health care or other purposes. The disposable self-steamingcomposition article may comprise a substantially planar laminatestructure having a single steam-generating heat cell or a plurality ofsteam-generating heat cells embedded between multiple material layersthat are laminated together. The steam-generating heat cell or cells maybe fixedly attached to the laminate structure. The self-steamingcomposition (such as, the composition in accordance with Example 1) isplaced within the cell or cells and a means for allowing oxygen into thecomposition is provided via a permeable layer on one or more sides ofthe composition. A suitable heat sealable film is apolypropylene/ethylene vinyl acetate (PP/EVA) film available from ClopayPlastics of Cincinnati, Ohio as material number DH245. The laminatestructure may be a nonwoven. In one non-limiting example the nonwovenmay be comprised of an SMS laminate (wherein “SMS” refers to aspunbond/meltblown/spunbond laminate). The meltblown portion may becomprised of one or more layers wherein at least one meltblown layerwill typically have a grammage of at least about 8 gsm. While notwishing to be bound by theory, it is believed that in self-steamingbenefit compositions utilizing carbon chemistry, a meltblown layerhaving a grammage of at least about 8 gsm in helps prevent carbon powderfrom exiting the article. A suitable nonwoven is available from PGI(Polymer Group International) of Waynesboro, Va. as material numberW502FWH.

In one non-limiting embodiment, a heat-sealable film is used for oneside of the steam-generating heat cell and this material is attached toa porous material (for example a highly porous nonwoven) to form thesteam-generating heat cell or cells. This highly porous constructionalso allows steam to be released from the article during use.

1. A method of making a composition comprising: (a) a fuel componenthaving; (b) a water manager component, wherein the mean particle sizedistribution of the water manager component is greater than about 250microns; and (c) water; wherein the composition is exothermic uponcontact with oxygen and is self-steaming; said method comprising mixingthe fuel component, the water manager component, and the water, whereinthe fuel component comprises carbon and wherein the method comprisesprewetting the carbon prior to mixing the carbon with the water managercomponent.
 2. The method according to claim 1 wherein the water managercomponent comprises a material selected from the group consisting ofvermiculite, porous silicates, wood powder, wood flour, cotton, paper,vegetable matter, absorbent gelling material, carboxymethylcellulosesalts, inorganic salts, and mixtures thereof.
 3. The method according toclaim 1 wherein the water manager component comprises absorbent gellingmaterial.
 4. The method according to claim 1 wherein the fuel componentcomprises a material selected from the group consisting of metals, metalsalts, and mixtures thereof.
 5. The method according to claim 1 whereinthe mean particle size distribution of the water manager component isfrom about 400 microns to about 800 microns and wherein the meanparticle size distribution of the fuel component is from about 100microns to about 300 microns.
 6. The method according to claim 1 whereinthe mean particle size distribution of the fuel component is at leastabout 100 microns.
 7. The method according to claim 1, wherein the meanparticle size distribution of the water manager component is at leastabout 400 microns.
 8. The method according to claim 1, wherein the fuelcomponent comprises iron, a metal salt, and activated carbon.
 9. Themethod according to claim 8 comprising from about 30% to about 95% ofthe iron, from about 0.5% to about 10% of the metal salt, from about0.5% to about 25% of the activated carbon, all by weight of thecomposition.
 10. The method according to claim 8, wherein the iron issponge iron.
 11. The method according to claim 1 comprising from about0.1% to about 30% of the water manager component, by weight of thecomposition.
 12. The method according to claim 1, further comprisingmixing in a volatile component to the composition.
 13. The methodaccording to claim 12 wherein the volatile component is selected fromthe group consisting of camphor, menthol, eucalyptus, peppermint,spearmint, methyl salicylate, bornyl acetate, lavender, ephedrine,angelica root, aniseed, basil, bay, bergamot, cajeput, cardamom, cassia,cedarwood, chamomile, sage, clove, cinnamon, coriander, cumin, fennel,frankincense, geranium, ho-wood, lemongrass, lemon, litsea, majoram,melissa, myrrh, myrtle, niaouli, neroli, nutmeg, orange, palmarosa,patchouli, pimento berry, pine needle, ravensara aromatica, rosewood,rosemary, tea tree, thyme, verbena, and mixtures thereof.